PREFACE

Theory is incomplete without practical. In a education system in which theory overrides

practical knowledge, the importance of an Industrial Training can not be underestimated. It
provides an insight about the industry, but most importantly bridges the gap between thought and
action. We were fortunate to get the precious opportunity of summer training at OIL Duliajan.

An engineering principle learnt in a classroom is always borne out by practical experience; it

creates a strange sense of excitement running into an old friend amongst crowd of strangers. The
pictures of all the pumps, compressors, engines, valves, etc., have we seen were right before us.

During the training, we witnessed how problems were diagnosed and solved. The technicians had
been working hands-on for years and this had given them something like an intuitive feel for the
work. Many of them learnt from their years of experience and practical knowledge although
without having any degree from a prestigious institute.

Although the period of 30 days was a bit short but we learnt how an industry runs and what is the
work of an engineer. It gave us a wide practical outlook of whatever we have got to learn till
now.

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 ACKNOWLEDGMENT
I would like to express my heartfelt gratitude to Oil India Limited for providing me with the
opportunity to undertake a 30-day internship at the Oil & Gas Production Services (OGPS)
Department. This experience has been invaluable in enhancing my practical knowledge and
understanding of the oilfield operations.
I extend my sincere thanks to the Human Resource – Learning & Development Department
for organizing and facilitating this internship program. I am especially grateful to Mr. Saurav
Paul, our Internship Coordinator, for his constant support, timely guidance, and coordination
throughout the internship period, ensuring a smooth and enriching experience.
I would also like to thank Mr. Rajib Pegu, Workover Technical Services, for his insightful
guidance and detailed explanations that helped us understand the technical intricacies of
workover equipment maintenance and operations.
A special note of thanks to Ms. Liza Dutta, for her mentorship and support during our visit to the
Secondary Recovery & Utility (SR & U) Section. Her detailed briefings on enhanced oil
recovery techniques and utility operations provided us with a comprehensive understanding of
this critical domain.
Lastly, I would like to thank all the OGPS personnel and field staff who shared their knowledge
and extended their cooperation during our departmental visits, making this internship a truly
enriching learning experience

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 ABSTRACT

This report presents a comprehensive account of the 30-day internship program undertaken at the
Oil & Gas Production Services (OGPS) Department of Oil India Limited. The internship
provided in-depth exposure to key operational divisions within OGPS, namely the Workover
Technical Services, Workover Operations, and the Secondary Recovery & Utility (SR & U)
Section. During the tenure, we gained practical insights into critical field operations such as well
intervention techniques, workover rig processes, equipment maintenance protocols, and enhanced
oil recovery methods. The structured visits across these departments enabled a holistic
understanding of OGPS's role in sustaining oil production from mature wells while ensuring
operational efficiency and safety. This report encapsulates the learnings, observations, and
technical knowledge acquired throughout the internship period

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 TABLE OF CONTENTS
1. Preface ……………………………………………………………………………………………………1
2. Acknowledgment …………………………………………………………………………………… 2
3. Abstract …………………………………………………………………………………………………. 3
4. Oil India Limited ………………………………………………………………………………………5
5. Work Over Technical Services ………………………………………………………………… 7
6. Work Over Operations ………………………………………………………………………… .30
7. Secondary Recover & Utility ……………………………………………………………………41.
8. Conclusion ………………………………………………………………………………………………57

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1.Oil India Limited (OIL):
1.1 COMPANY PROFILE
Oil India (OIL) is a large state-owned oil and gas company in India under the administrative
control of the Ministry of Petroleum and Natural Gas of the government of India. OIL is engaged
in the business of exploration, development and production of crude oil and natural gas,
transportation of crude oil and production of liquid petroleum gas. From the discovery of crude
oil in the far east of India at Digboi , Assam in 1889 to its present status as a fully integrated
upstream petroleum company, OIL has come far, crossing many milestones.

OIL is the pioneer in exploration and production of hydrocarbons in India, and traces its roots
back to Oil India Private Limited formed in 1959 with The Burmah Oil Company Limited
holding two-thirds of equity and Government of India holding one-third. Oil India Private
evolved into Oil India Limited, which was an equal partnership between Burmah Oil and
Government of India. In 1983 the company became a public sector undertaking of the
Government of India.

The Company has over 1 lakh sq. km. of license areas. Its exploratory efforts has led to
discovery of 85 oil & gas fields with total established in-place reserves of 842 MMT of oil and
oil equivalent of gas as on 01.04.2002.The Company presently produces over 3.3 MMTPA of
crude oil, over 5 MMSCMD of Natural Gas and over 50,000 Tons of LPG annually. Most of this
emanates from its traditionally rich oil and gas fields concentrated in the North-Eastern part of
India and contributes to over 65% of total oil gas produced in the region. The search for newer
avenues has seen OIL spreading out its operations in onshore / offshore Orissa and Andaman,
deserts of Rajasthan, plains of Uttar Pradesh, riverbeds of Brahmaputra and offshore Saurashtra.
In Rajasthan, OIL discovered gas in 1988, heavy oil / bitumen in 1991 and started production of
gas in 1996.OIL is also constructing a pipeline for transportation of finished petroleum products
which is expected to be commissioned in 2007.

OIL has participating interests either alone or in consortium in 14 NELP Blocks of which it is the
operator in six. OIL also is operator in two exploration blocks in Libya which it recently won in
consortium with M/s. IOC and has participating interests in a pipeline in Sudan with OVL and in
an exploration service contract in offshore Iran with OVL & IOC. It is a duty of OIL to do its
business operation within the objectives specified in the Memorandum & Articles of Association
in a most fair and transparent manner OIL is committed to achieve its goals as enshrined in the
Vision & Mission Statement of the Company.

1.2 Learning and Development Centre

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As a part of development of Human Resources. The Management Training and
Development Centre (MTDC) for Executives (established in 1995) and the Oil Training
Institute (OTI) for the Non-executives (established in 1997), have been set up to cater to
company's operational requirements. The institutes not only offer services to the
Company (currently having strength of 8800 employees) but also to other industries in
the Northeast India for development of contemporary management practices and
application, workmen training and skill up gradation. MTDC also provides summer
training to students from different Engineering Colleges and other
Institutes/Universities.

1.3 OGPS Department, Oil India Limited (Duliajan):

OGPS plays a vital role in ensuring continuous, efficient oil and gas production from
aging fields, especially in regions with logistical and geological challenges. Its strategic
focus on safety, advanced well intervention technologies, and efficient resource
utilization contributes significantly to OIL’s overall production reliability.

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 2. WORK OVER TECHNICAL SERVICES

The Workover Technical Services (WOTS) division of Oil India Limited (OIL) plays a pivotal
role in supporting the company’s well intervention and production enhancement activities. As
part of the broader Oil & Gas Production Services (OGPS) Department, WOTS is primarily
responsible for the planning, coordination, and technical execution of workover operations in
aging and underperforming wells.
The division oversees the maintenance, refurbishment, and readiness of critical equipment and
tools such as workover rigs, mast assemblies, hoisting systems, draw-works, rotary tables, and
associated mechanical and hydraulic systems. WOTS also provides technical assessments,
troubleshooting support, and field assistance to ensure smooth and efficient workover activities.
Additionally, the team is involved in the inspection and certification of workover units,
maintaining a high standard of operational safety and compliance with industry best practices. By
ensuring the availability and reliability of workover assets, WOTS significantly contributes to
sustaining production levels, extending the lifecycle of mature wells, and minimizing operational
downtime.

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2.1 Rig Layout

The basic layout of all the equipment’s and tools of a drilling rig is explained by the block
diagram given below:

Nomenclature of the Rig components:

1. Power Pack: It consist of 4 separate engines which are coupled to alternators which serve
the purpose of generating alternating current.
2. Fuel storage tanks: These are high capacity tanks (40KL) used for storage and supply of
fuel (HSD) to the engines around the rig.

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 3. Power control room(PCR): Electrical device which are connected to the power pack
servicing the purpose of controlling the amount of current from power pack to the engines
to the rig depending upon the requirements.
4. Air Compressor Hut: It consist of three numbers of compressors which produces
pressurized air which is to be supplied to the power pack and other equipment’s.
5. Water tanks: These tanks serve the purpose of storing fresh underground water .There
are two gauging tank and one booster tank.
6. Barites Rack: Storage shed which is used to store various chemicals.
7. Mud Hooper: It’s a device for preparing muds.
8. Chemical storage tanks: Three storage tanks used to store the muds, each having two
Agitators.
9. Suction tank: The tank which is connected to the suction line of the rig or mud pump.
10. Intermediate Tank: The tank which are fitted with tools like Desilter and Desander ,
used to remove sand and slit from mud mixture.
11. Cementing Silos: These are used to store the cements required for cementing job at the
well-site.
12. Gensets: Two additional power units required to meet the requirements of electricity
when the power packs are in the idle state. They are in two numbers having capacity
63KVA and 30KVA respectively.
13. Mast: It is used to drilling the hole which houses the draw-works , rotary table
arrangements for stacking the drilling pipes and other drilling equipment.
14. Pit: These are areas where wastage of the whole drilling operations is to be accumulated
for the treatment before disposal. These are retainer pit, effluent pit, and main pit.

The above components are supported/driven/operated by engines and pumps which are
mentioned below with quantities:

 Decanting pump (2 nos): These are gear pumps used

for the purpose of supplying fuel to the engines when
the level of HSD decrease and the fuel cannot flow
itself due to low hydrostatic pressure heads.

 Booster pump (2 nos): These pumps are used to provide high discharge of water from
the water storage tank to the other components of the rig for drilling related
operations.
 Source Water pump (2 nos): These are used to extract the ground water and store it
in the water tanks also maintaining water level in the tanks.
 Gauging water pumps(2 nos):These pumps supply the chemical treated water for
cementing jobs at well- site.
 Mud mixer pump(2nos):These pumps are responsible for producing a homogenous
drilling fluid(mud).
 Agitators(17 no):These rotors are
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 present over the booster water, gauging
water and mud tanks. The main
purpose is stirring the fluid to prevent
its contents from precipitating.
 Desander: A centrifugal device for
removing sand from drilling fluid
to prevent abrasion of the pumps.
It may be operated mechanically or
by a moving stream of fluid inside a
special cone-shaped vessel, in which
case it is sometimes called hydro
cyclone.

 Desilter: A centrifugal device, similar to a desander, used to remove very fine

particles, or silt from drilling fluid. This keeps the amount of solids in the fluid to the
lowest possible level.[fig no.06]
 Pit Pump(1 nos):This pumps is used to transfer the waste of the drilling operation to
the pits for treatment before disposal.

2.2 Pump:
Defination:

 A device that uses an external power source to apply force to a fluid in order to move it
from one place to another.
 Must overcome:
1. Frictional from large quantities of fluids.
2. Difference in static pressure between two locations.
 Must provide any velocity desired.

Net Positive Suction Head(NPSH):

NPSH can be defined as two parts:

1.NPSH Available(NPSHA): The Net Positive Suction Head available from the application to
the suction side of a pump is often named NPSH a. The NPSHa can be estimated during the design
and the construction of the system, or determined experimentally by testing the actual physical
system.

For a common application - where the pump lifts a fluid from an open tank at one level to
another, the energy or head at the surface of the tank is the same as the energy or head before the
pump impeller and can be expressed as:

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h0 = h s + h l

where

h0 = head at surface (m, in)

hs = head before the impeller (m, in)

hl = head loss from the surface to impeller - major and minor loss in the suction pipe (m, in)

2.NPSH Required(NPSHR): The NPSHr , called as the Net Suction Head as required by the
pump in order to prevent cavitation for safe and reliable operation of the pump.The required
NPSHr for a particular pump is in general determined experimentally by the pump
manufacturer and a part of the documentation of the pump.

NPSHA is a function of your system and must be calculated, whereas NPSHR is a function of the
pump and must be provided by the pump manufacturer. You must have more suction side
pressure available than the pump requires.

The available NPSHA of the system should always exceed the required NPSHR of the pump to
avoid vaporization and cavitations of the impellers eye. The available NPSHA should in general
be significant higher than the required NPSHR to avoid that head loss in the suction pipe and in
the pump casing, local velocity accelerations and pressure decreases, start boiling the fluid on the
impeller surface.
It can be expressed as : NPSH = hs - hv
NPSH = ps / γ + vs2 / 2 g - pv / γ
Where NPSH = Net Positive Suction Head (m, in)

2.2.1 Classification of Pumps

Types of pumps:
1.Positive displacement Pumps.
2. Centrifugal pumps.
1.Positive Displacement Pumps:
Positive-displacement pumps are another category of pumps. Types of positive displacement
pumps are reciprocating, metering and rotary pumps. Positive –displacement pumps operate
by forcing a fixed volume of fluid from the inlet pressure section of the pump into the
discharge zone of the pump. These pump generally tend to be larger than the equal capacity
dynamic pumps .Positive-displacement pumps frequently are used in Hydraulic system at
pressure at pressure ranging up to 5000 psi.

A. Reciprocating Pumps:
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  The Reciprocating pumps is basically a slider crank Mechanism.
 The complete cycle follows simple harmonic motion.
 Fluid is sucked at the beginning of the cycle and discharged at an elevated pressure
at the end of the cycle.

B. Rotary Pumps:

Another type of pump we find abroad ship is rotary pump. Rotary pumps are capable of
pumping more fluid than reciprocating pumps of the same weight. A number of types are
included in the classification ,among which are the gear pumps, the screw pumps and the
moving vane pumps .Unlike the centrifugal pump rotary pump is a positive-displacement
pump. This means that for each revolution of the pump, a fixed volume of fluid is moved
regardless of the resistance against which the pump is pushing .As we can see , any blockage
in the system could quickly cause damage to the pump or a rupture of the system. You, as a
pump operator, must always be sure that the system is properly aligned so a complete flow
path exists for a fluid flow. Also because of their positive displacement feature, rotary pump
requires a relief valve to to protect the pump and piping system. The relief valve lifts at a
pre-set pressure and returns the system liquid either to the suction side of the pump or back
to the supply tank or pump.

2. Centrifugal Pump:

 A centrifugal pump imparts energy to the liquid by its centrifugal action.

 Its purpose is to convert energy if an electric motor/engine into velocity or kinetic energy
and then into pressure energy of a fluid that is being pumped.

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  Centrifugal pumps are generally used where high flow rate and moderate head increase
are required.

Types of Centrifugal Pumps:

A. Single stage centrifugal pump

Single stage centrifugal pump is one which

has only one impeller attached to the shaft.
They are used in place where low head and
low discharge rate is required.

B. Multi-stage centrifugal pump

Multi-stage centrifugal pump is one which

has more than one impeller attached to a
single shaft. They are used in place where
high head and high discharge is required.

Whenever the head requirement is large, multistage pumps are used in order to produce high head
in single stage, the impeller dia, speed & power requirement should be more which causes
undesirable condition like excessive vibration, large space, power loss, less efficiency hence
multistage pump which consist of more than one impeller should be used to increase head
gradually in each stage to produce high head.
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 4 –Stage centrifugal Pump

Fig No: 11

Casing design of centrifugal pump:

According to the type of casing centrifugal pump have two basic types:

A. Volute casing: In order to increase the pressure head, the velocity of the fluid is decreased it
is done by gradually increasing the area of the casing from the impeller outlet.

B. Concentric Casing: If a chamber known as vortex is introduced between the impeller and
chamber then the casing is called concentric casing .Its main function is to convert the
kinetic energy into pressure Energy.

2.2.2 Positive Dispacement Pumps in the Rig.

The followings positive displacement pumps were observed and studied by me during my
visit to various oil wells at Oil India Limited, Duliajan.

Mud or Rig Pumps(2 nos): Two large triplex single acting reciprocating pump are used
to circulate the mud upto of 7500 psi(5200kpa).
Classification
 According to the acting type:
Mud pumps can be divided into single-acting pump and double -acting pump according to
the completion times of the suction and drainage action in one cycle of the pistons
reciprocating motion.
 According to the quantity of liners(piston/plunger):

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 Mud pumps come in variety of sizes and configurations but for the typical petroleum
drilling rig, the triplex (three piston/plunger) mud pump is the pump of choice. Duplex
mud pumps (two piston/plunger) have generally been replaced by the triplex pump, but
are still common in developing countries.

Composition

The Mud pumps consists of two main sub-assemblies, the fluid end and the power end.

 Herringbone gears also called double

helical gears, are gear sets designed to
transmit power through parallel or
less commonly perpendicular axes. The
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 unique tooth structure of a herringbone
gear consists of two adjoining, opposite
helixes that appear in the shape of the
letter V.It is used to transfer the
power from the pinion shaft of motor
to the crankshaft.

 Bearings with their Description:

1.Cylindrical Roller Bearing-Both Radial And Axial Load At High Rpm.

2.Needle Roller Bearing-Only Radial Load At Medium Rpm.

3.Tapered Roller Bearing-Both Radial And Axial Load At Medium Rpm

4.Self Aligning Roller Bearing-Both Radial and Axial load at low RPM.

2.2.4 Accessories attached to the rig pump.

Suction Dampener:

 Suction stabilizers are designed to stabilize the velocity variation of the pump suction feed
stream.
 The performance is based on its ability to store and release fluid to reduce the velocity
variation to the pump suction manifold. The residual peak-to-peak flow induced pressure
variation (DP) is a function of the fluid velocity variation in the suction piping. Suction
stabilizers reduce the velocity variation in the suction piping by its ability to store and
release fluid to meet the pumps demand for fluid.

Delivery or pulsation Dampener:

 Pulsation Dampeners are designed to stabilize the velocity variation of the mud pump.
 Performance is based on its ability to store and release fluid to reduce the velocity
variation in the discharge piping system.

2.2.5 Description and Specifications of the pump at the Rig.

Type: Motor Driven

Make: National oil well Varco
Model No:12-P-160
No. of Cylinders:3
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 Maximum Liner Size:7.25” at stroke 12”\
Rated Maximum power input:1600 H.P at 120 S.P.M
Rated maximum power output:1440 H.P. at 120 S.P.M

Water Pump (1no.):

Type: Engine: Driven

Manufacturer: Voltas
No. of Cylinders:4
Duplex double acting plunger type Pump.

2.2.6 Centrifugal pumps at the rig.

There are different makes and models of centrifugal pump at Drilling Technical Service Section
that are used at the well –site for drilling and other relate operation. They are named according to
their application at the well site .The most commonly used pumps are Tengl Mission Make.

 Supercharger pump (2nos)

 Desander & Desilter pump (2 nos)
 Mud Mixing pump(2 nos)
 Booster pump(2 nos)
 Gauging water pump(1)
 Submersible (1no)

Booster Pump (2 nos)

 Make: Beacon weir

 Model no:80UP100
 Maximum RPM:1450
 Power Rating:30 H.P
 Frequency:50 Hz
 Discharge:95m/hrs
 Total head:32 m
 Delivery pipe diameter:100mm
 Suction pipe diameter:80mm
 No of stages:1
 Design: Horizontal split casing.

Superchargers, Mud mixers, desanders and desilter

 Make: Mission
 Model no: Magnum-I
 Maximum RPM:1750
 Power rating:100 B H P

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  Delivery pipe diameter:6”
 Impeller Blade size:14”

Submersible pump(1 no)

 Make: KSB
 Model No:CORA7C
 No of stages:7
 Discharge:10KL/hr
 Input power:1.5 H.P
 Frequency:50Hz

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2.3 Engines:
An engine or motor is a machine designed to convert energy into useful mechanical motion. Heat
engines, including internal combustion engines and external combustion engines burn a fuel to
create heat, which then creates motion. Electric motors converts’ electrical energy into
mechanical motion, pneumatic motors use compressed air and other, such as clockwork motors in
wind-up toys-use elastic energy .In biological systems, molecular motors, like myosin in muscles,
use chemical energy to create motion.

Internal Combustion Engine

The internal combustion engine is an engine in which the combustion of a fuel occurs with an
oxidizer (usually air) in combustion chamber that is an integral part of the working fluid flow
circuit .In an internal combustion engine the expansion of the high temperature and high pressure
gases produced by combustion apply direct force to some components of the engines. The force
is applied typically to piston turbine, blades, or a nozzle .This force moves the components over a
distance transforming chemical energy into useful mechanical energy .The first commercial
successful internal combustion engine was created by Etienn Lenoir.

Basic Engines Parts

 Valves
 Exhaust valve lets the exhaust gases escape the combustion.
 Intake valve lets the air or air fuel mixture to enter the combustion
chamber.(Diameter is larger than the exhaust valve).
 Cam shaft
 The shaft that has intake and exhaust cams for operating the valves.
 Cylinder head
 It contains the cooling fins or water jackets and the valves.
 Cam lobe
 Changes rotary motion to reciprocating motion.
 Piston
 A movable part fitted into a cylinder, which can receive and transmit power.
 Through connecting rod, forces the crank shaft to rotate.
 Engine Block
 Foundation of engines and contains pistons, crank shaft, cylinders, timing
sprockets and sometimes cam shaft.
 Crank shaft
 Coverts up and down or reciprocating motion into circular or rotary motion.
 Flywheel
 Attached to the crankshaft
 Reduces Vibration
 Used during initial start-up
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  Transfer power from engine to drive train.

2.3.1 Engine components

1. Turbo chargers:
A turbocharger is a supercharger that is driven by the engine's exhaust gases, by means of a
turbine. It consists of a two piece, high—speed turbine assembly with one side that compresses
the intake air, and the other side that is powered by the exhaust gas outflow. When idling, and at
low-to-moderate speeds, the turbine produces little power from the small exhaust volume, the
turbocharger has little effect and the engine operates nearly in a naturally aspirated manner.
When much more power output is required, the engine speed and throttle opening are increased
until the exhaust gases are sufficient to ‘spin up’ the turbocharger's turbine to start compressing
much more air than normal into the intake manifold. Turbo charging allows for more efficient
engine operation because it is driven by exhaust pressure that would otherwise be (mostly)
wasted.

2.Governor:
The purpose of the Governor is to control the diesel engine speed by regulating the amount of
fuel injected. This governor regulates speed by controlling the position of the fuel control rack.
The speed control lever on the governor is positioned by the operator using some type of control
lever, cable, or remote air actuator. Modern diesel engines utilize an electronic governing and
control system. The electronic control module (ECM) is engine mounted & used in conjunction
with unit fuel injectors that are electronically controls. The governor regulates speed by
controlling the activation of the electronic solenoid on the unit fuel injector. Speed setting can be
remotely set with various electrical devices. Function such as air fuel ratio, shutdown function, &
altitude sensing are electronically controlled in the ECM.

3. Radiator:

A radiator is a type of heat exchanger. It is designed

to transfer heat from the hot coolant that flows
through it to the air blown through it by the fan. Most
modern cars use aluminum radiators. These radiators
are made by brazing thin aluminum fins to flattened

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aluminum tubes. The coolant flows from the inlet to the outlet through many tubes mounted in a
parallel arrangement. The fins conduct the heat from the tubes and transfer it to the air flowing
through the radiator.

4. Thermostat valve:
Any liquid-cooled engine had a small device called the thermostat that sits between the engine
and the radiator .It's main job is to allow the engine to heat up quickly, and then to keep the
engine at a constant temperature.
It does this by regulating the amount of water that
goes through the radiator. At low temperatures, the
outlet to the radiator is completely blocked - all of
the coolant is re circulated back through the engine.
Once the temperature of the coolant rises to between
180 and 195 F (82 - 91 C), the thermostat starts to
open, allowing fluid to flow through the radiator.
By the time the coolant reaches 93- 103 C, the
thermostat is open all the way. Fig No: 18

5.Firing order:
The firing order is the sequence of power delivery of each cylinder in a multi-cylinder
reciprocating engine. This is by the sequence of fuel injection in a Diesel engine. When designing
an engine, choosing an appropriate firing order is critical to minimizing vibration, to improve
engine balance and achieving smooth running, for long engine fatigue life and user comfort, and
heavily influences crankshaft design.

6. Air Starter:
Compared to a gasoline (petrol) engine, a Diesel engine has a very high compression ratio, an
essential design feature, as it is the heat of compression that ignites the fuel. An electric if starter
with sufficient power to "crank" a large Diesel engine would itself be so large as to be
impractical, thus the need for an alternative system. When starting the engine, compressed air is
admitted to whichever cylinder has a piston just over top dead center, forcing it a downward. As
the engine starts to turn, the air-start valve on the next cylinder in line opens to continue the
rotation. After several rotations, fuel is injected into the cylinders, the engine tarts
running and the air is cut off.

7. Fuel injection:
Fuel injection is a system for admitting fuel into an engine. The primary difference between
carburetors and fuel injection is that fuel injection atomizes the fuel by forcibly pumping it
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through a small nozzle under high pressure, while a carburetor relies on suction created by intake
air accelerated through a venturi tube to draw the fuel into the airstream. Most fuel injection
items are for gasoline or diesel application.

8. Mechanical Governor:

A flyweight assembly is used to detect engine speed. Two flyweights are fitted to a plate or ball
head which rotates about a vertical axis driven by a gear wheel. The action of centrifugal force
throws the weights outwards; this lifts the vertical spindle and compresses the spring until an
equilibrium situation is reached. The equilibrium position or set speed may be changed by the
speed selector.
As the engine speed increases the weights move outwards and raise the spindle; a speed decrease
will lower the spindle. The hydraulic unit is connected to this vertical spindle and acts as a power
source to move the engine fuel controls. A piston valve connected to the vertical spindle supplies
or drains oil from the power piston which moves the fuel controls depending upon the flyweight
movement. If the engine speed increases the vertical spindle rises, the piston valve rises and oil is
drained from the power piston which results in a fuel control movement. This reduces fuel supply
to the engine and slows it down. It is, in effect, a proportional controller.

WORKING OF THE FUEL INJECTION SYSTEM:

Most of the diesel fuel injector use the same basic deign.The injector assembly has several main
parts. The nozzle assembly is made of a needle and a body. A pressure spring and a spindle
hold the needle on the seat on the nozzle body. A nozzle holder sometimes called injector body
may allow for mounting the injector on the engine and some methods of adjusting in the spring
force applied to the needle valve the injection pump delivers fuel to the injector. The fuel passes
through a drilling in the nozzle body to a chamber above where the needle valve seats in the
nozzle assembly. As fuel pressure in the injector gallery rises it acts on the tapering portion of the
needle valve increasing the pressure until it overcomes the force from the spring and lifts the
needle valve from its seat. The highly pressurized fuel enters the engine at a high velocity in an
atornised spray. As soon as the delivery from the pump stops pressure under the needle in the

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tapering portion stops and the spring force pushes the needle down on the seat cutting off the fuel
supply to the engine.
Some of the fuel is allowed to leak between the nozzle, needle and the body to cool and lubricate
the injector. This fuel is collected by the leak offline and return to the fuel tank for later use.

8.Fuel priming pump:

Diesel fuel priming pumps ensure that the high-pressure injection pump has an adequate fuel
supply and pressure at its inlet. Typically used just prior to cranking the engine until a
mechanically driven low—pressure pump takes over.
 Functions Of Diesel Engines In Rigs
They are employed as prime mover for:
 Power Generation
 Lifting of water from source water well.
 Prime mover for auxiliary equipment.
 Diesel Engines Used In Drilling Rigs
 Caterpillar Engine:
 Used for Main power generation.

 Ruston and Hornby Engine:

Used as prime –over
i. For effluent pump
ii. For mechanical compressor and source water pump.

2.3.2 Caterpillar Engine.

Page | 23
 Fig No: 20

General Specifications

 Make : Caterpillar
 Power rating : 1320 WA
 Voltage : 220 to 13800V
 Frequency : 50 HZ
 Speed : 1000 RPM

 Engine Specifications
 Model : 3512 B, V-12 4 Stroke Water Cooled
 Fuel : Diesel
 Bore : 170 mm
 Displacement : 51.8L
 Stroke : 190.00 mm
 Compression ratio : 14:1
 Governor : Adem3(ECM)
 Fuel System : Electronic Unit Injection
 Firing Order : 1-12-9-4-5-8-11-2-3-10-7-6

1.Electronic Control System Components :

It is used for main power generation for drilling operation at the well-site. The B- series of
Caterpillar is fully automated and have various sensors on the Electronic Control Module (Ecm).

The Electronic control Module (ECM) Is the "Brain" Or Centre of Engine Control System. The
ECM use the information generated by the sensors which are located throughout the engine and
transmission to monitor all aspects of Engine operation. Connected to the ECM by the wiring
harness, the sensors detect and convert changes in pressure, temperature or mechanical
movement into electrical signals. The electrical signals are sent to the ECM.The ECM uses
information such as desired engine speed, and load to determine the fuel injection pressure,
timing and duration. Based on sensor inputs, the ECM actuates the individual unit injectors to
control engine speed.

Page | 24
 The CAT Marine Power Display(MPD)

*Zero represents that the sensors (air inlet,turbo inlet) are not activated.

5.3 GENSETS (30 KVA and 63KVA)

Due to high fuel consumption rate of the caterpillar engine, it is operated to meet the alternating
current requirement of the drilling and other related activities. During the idle state of the engine
the demand for electric current is fulfilled by gensets having capacities of 30 kVA and 63 kVA.It
is operated to meet the baic current need such as lightings, maintenance work and running few
small pumps.

 30 kVa set (2 Nos.)

This consist o f two numbers of engines
Specifications:
1. Engine Make :Escorts
2. Model : G-30-ll
3. Engine Power : 43 BHP.
4. Rated Speed : 1500 RPM.
5. No. of Cylinder :3
6. Engine Bore & Stroke Size : 91X11O mm.
7. Lube OIL Sump Capacity : 6.5 Liters.
8. Compression Ratio : 17.5:O1
9. Aspiration : Turbo Charged.
10. Cooling System : Water/ Coolant.

 63kVa set (2 Nos.)

Engine Specifications:
1. Make : Greaves
2. Model : 6YDA MK]!
3. Power : 103.4
Page | 25
4. Speed : 1800 RPM
5.. Bore : 4.375”
6. Stroke : 5"
7. No. of cylinders :26
8. Lube sump capacity: 16.2 Liters
9. Lube oii Grade : 20W4O
10. Fuel pressure : 15 Psi

2.3.3 Compressors:
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air. By one of several
methods, an air compressor forces more and more air into a storage tank, increasing the pressure.
When tank pressure reaches its upper limit the air compressor shuts off. The compressed
air,then,is held in the tank until called into use.
The two basic types of air compressors are:
1.Reciprocating type.
2. Rotary screw type
These types are further specifed by:

1.Cooling method (air,water,oil)

2.Drive method(motor, engine, steam, other)
3.Lubrication(Oil,Oil- Free where Oil Free means no lubricating oil contacts the compresed air)

 The reciprocating compressor have the same working as the pump and engines.

Rotary Screw Compressors:

Rotary Screw Compressors are positive
displacement compressors. The most
common rotary air compressor is the
single stage helical or spiral lobe
oil flooded screw air compressor.
These compressors consist of two
rotors within a casing where the
rotors compress the air internally.
There are no valves. These units
are basically oil cooled (with air
cooled or water cooled oil coolers)
where the oil seals the internal clearances.

Compressors present in the Rig.(30 nos.)

Rotary screw type(2 nos)

It’s a motor Driven Compressor.
Page | 26
Specifications:
Make: Ingersoll rand
Model: UP5-22-10
Maxim mum allowable Pressure : 10 Bar
Motor power : 22 kW
Capacity (cu M/min):3.11
Current: 43 Amps
Voltage: 400V

 Reciprocating type (1 no):

It is a Engine Driven Compressor.
Specification of Engine:
Make: Ruston
Model : 3YDA
No. of Cylinders: 3
Fuel: Diesel, air cooled
Power: 42.1 H.P
Speed: 1450 RPM
Lube Oil grade: 2OW4O

 Specification of the Compressor:

Make : Ingersoll rand
Model : 3000
No. of Stages :2
Type :30
Power :30 H.P
Maximum working pressure : 250 Psi 3
Average working Pressure : 120 Psi ‘ 9
Lube oil Capacity : 13.21 CFM
Lube Sump Capacity : 5 Liters

Compressed Air Storage Tank :

This tank is used to store the compressed air so that it can be used when needed.
Tested Pressure : 225 psi
Working Pressure : 150 Psi
The testing pressure is determined as a safety measure in the Rig. It is calculated by the given
Formula:
For Air
Testing Pressure = 1.5

Page | 27
 3. WORK OVER OPERATIONS

Oil and gas wells, especially older ones, often need major repairs or upgrades to keep
them producing efficiently. This set of procedures is called workover operations, which
companies like Oil India Limited (OIL) carry out regularly, especially in mature fields.
Let’s look at the most common workover operations — simply explained, but with the
proper technical terms where needed

3.1 Well Killing

Well killing is a fundamental operation performed before any workover or intervention
activity begins. It involves temporarily suppressing the natural pressure from the
reservoir to ensure the well is safe to work on. Without proper well killing, any downhole
operation could be extremely hazardous, risking uncontrolled flow of formation fluids —
known as a blowout.
The process requires pumping a specially prepared kill fluid (usually a high-density
drilling mud or brine) into the wellbore until the hydrostatic pressure of the fluid column
exceeds the formation pressure. This ensures that formation fluids (oil, gas, or water) do
not enter the wellbore during the operation. The kill fluid must be carefully designed,
considering the mud weight, well depth, bottom hole pressure, and type of fluid in the
formation.
Different methods of killing a well include bull heading (pushing the kill fluid directly into
the reservoir), reverse circulation (pumping from the annulus and taking returns
through the tubing), and lubricate and bleed techniques (used when pressure needs to
be reduced gradually).
In companies like Oil India Limited, proper well killing is critical for safe and efficient
workover operations. It ensures that any downhole equipment removal, tubing change,
or other repair work can be done without the risk of uncontrolled fluid flow or formation
damage.

3.2 Recompletion
Recompletion is the process of modifying an existing well to allow it to produce from a
different reservoir or zone than it was originally completed for. This is commonly done in
mature fields where the initial producing zone has been depleted, damaged, or has
become uneconomical to produce.
Recompletion involves isolating the original zone — often by setting mechanical
packers, bridge plugs, or performing cement squeeze operations — and then
perforating a new productive zone within the same wellbore. This avoids the need to
drill a new well, making recompletion a cost-effective solution for maximizing reservoir
access.
Page | 28
The new target formation may be above or below the original zone. Engineers evaluate
well logs, production history, and reservoir characteristics before
choosing a new interval. Techniques like tubing conveyed perforation (TCP) or
wireline perforation guns are used to connect the new pay zone to the wellbore.
Sometimes, dual completions are done to simultaneously produce from two zones.

In Oil India Limited’s operations, where many wells are in multilayered reservoirs,
recompletion plays a significant role in optimizing field output. It allows the company to
tap into bypassed or untapped reserves, thus enhancing the recovery factor of the asset
without major drilling investments.

3.3Reformation
Reformation in oilfield workover operations refers to modifying, restoring, or
restructuring the internal design and components of a wellbore to extend its useful life
and improve performance. Over time, wells are exposed to various stresses — including
corrosion, scale build-up, tubing collapse, and mechanical wear — all of which can
hinder production or pose safety risks.
During reformation, the damaged or outdated components of the well are removed and
replaced. This may involve pulling out the tubing string, replacing corroded casings, or
milling out unwanted obstructions such as collapsed pipe or cement. In cases where
equipment or debris has fallen into the well, fishing tools are used to retrieve them.
Sometimes, reformation includes changing the completion type — such as converting
from open-hole to cased-hole completions, or modifying the artificial lift system (e.g.,
from sucker rod pump to electric submersible pump). In complex scenarios, side tracking
the well — i.e., creating a new pathway within the same bore — may be considered to
bypass damaged zones.
For a company like Oil India Limited, which operates many old wells, reformation
ensures that aging infrastructure remains functional and productive. It is an essential
strategy for maintaining well integrity, avoiding downtime, and maximizing return on
earlier investments

3.4Stimulation
Stimulation is a workover technique used to enhance the flow of hydrocarbons from a
formation to the wellbore by removing formation damage or improving permeability.
Page | 29
Even when oil or gas is present in the reservoir, it may not flow freely into the well due
to tight rock structure, clogging, or skin damage caused by drilling mud, scale, or clay.
There are two main stimulation methods: acidizing and hydraulic fracturing. Acidizing is
typically used in carbonate or sandstone reservoirs, where hydrochloric acid (HCl) or
mud acid is pumped into the formation to dissolve

blockage materials and clean the perforation tunnels. This method is called matrix
acidizing when done at pressures below fracture pressure.
In hydraulic fracturing, fluid mixed with proppants (like sand or ceramic particles) is
injected at high pressure to fracture the rock, creating new flow channels. The
proppants hold these fractures open, allowing oil or gas to move more freely toward the
wellbore.
Stimulation is crucial in reviving low-producing wells or wells with near-wellbore
damage. In fields operated by Oil India Limited, particularly those with tight or complex
formations, stimulation treatments are used strategically to boost well productivity and
reservoir recovery with minimal cost compared to drilling new wells.

3.5Squeeze Cementing
Squeeze cementing is a remedial operation conducted to seal off undesirable zones,
repair casing leaks, or restore zonal isolation in a well. It involves injecting cement
slurry under pressure into specific parts of the wellbore or formation, usually through
perforations, casing cracks, or behind-the-casing channels, until the slurry is squeezed
into the problem zone and allowed to set.
The main goal is to block the movement of unwanted fluids — such as water or gas
intrusion — or to prevent cross-flow between formations. The operation begins with
preparing the well by isolating the target zone using bridge plugs or packer systems,
then pumping the cement through tubing and monitoring pressure to ensure correct
placement.
Squeeze cementing requires a deep understanding of wellbore geometry, fluid
dynamics, and cement properties. If not done properly, it can lead to poor zonal
isolation or failed plugs. After the cement sets, pressure tests and well logging are often
done to verify success.
In operations like those of Oil India Limited, squeeze cementing is especially important
for maintaining well integrity in aging fields. It helps extend the operational life of wells
by repairing leaks and ensuring that only the desired contribution to production.

Page | 30
 3.6 RIG BASIC COMPONENTS

3.6.1 Rig Engine

The rig engine is the primary power source of the drilling rig. It drives major systems
such as the hoisting system, rotary table, and mud pumps, typically using diesel or gas
engines.

3.6.2 Derick / Mast

The derrick or mast is the tall steel structure that supports the drilling string and hoisting
system. It provides the vertical clearance needed to handle long sections of pipe.

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 3.6.3 Derick Floor / Sub Structure
The derrick floor is the main working platform of the rig where drilling operations occur.
The substructure is the base framework that elevates and supports the derrick and
provides space below for blowout preventers and other equipment.

3.6.4 Hoisting System:

This system includes the drawworks, crown block, traveling block, and wireline. It is
responsible for raising and lowering the drill string and other heavy equipment in and out of the
well.

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 3.6.5 Rotary Table

The rotary table is mounted on the rig floor and rotates the drill string and bit, enabling drilling
into the formation. It’s a key part of the rotary drilling system

3.6.6 Mud Pump

The mud pump circulates drilling fluid (mud) down the drill string and back up the annulus. It
helps cool the bit, carry cuttings, and control formation pressure

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 3.6.7 Blowout Prevention Equipment (BOPE)
BOPE is a collection of valves and tools used to seal the well and prevent uncontrolled flow of
formation fluids during drilling, commonly known as a blowout.

3.6.8 BOP Control Unit

This unit provides the hydraulic or pneumatic power to operate the BOPs. It allows for remote or
manual control of the BOPs during a pressure event.

Page | 34
 3.6.9 Choke and Kill Manifold
This system consists of a network of valves and pressure gauges used to control well pressure
during kicks. It allows controlled release or pumping of fluids into the well to stabilize it.

3.6.10 Trip Tank

A trip tank is a small, calibrated tank used to accurately measure the volume of drilling fluid
(mud) entering or leaving the well during tripping operations—when drill pipe is inserted or
removed. Its main purpose is to detect any unexpected gain or loss of fluid, which could
indicate a kick (formation influx) or losses to the formation, helping maintain well control.

3.6.11 Christmas tree

A Christmas Tree is an assembly of valves, spools, and fittings installed on top of a completed oil
or gas well. Its primary function is to control the flow of hydrocarbons from the well to surface

Page | 35
facilities and to allow for well monitoring and maintenance. It also supports pressure control,
injection operations, and safe shutdown of the well when necessary.

3.7

Page | 36
 WORKOVER EQUIPMENTS AND TOOLS

1. Drilling pipe
A steel pipe used to transmit torque and drilling fluids from the surface to the drill bit.
It's essential for both drilling and workover operations.

2. Hydraulic Jar
A downhole tool designed to deliver a sudden jarring force (impact) to help free stuck
tools or pipe. It uses hydraulic delay mechanisms to store and release energy

3. Swivel Joint Assembly

A mechanical device that allows rotation of the pipe or tool string while maintaining a
pressure-tight seal, enabling circulation of fluids during rotation

Page | 37
4. Safety or Kelly
Kelly Cock is a type of valve installed either above or below the Kelly (a square or
hexagonal pipe used to turn the drill string) on a drilling rig.

Page | 38
 5. Drilling jar

Similar to a hydraulic jar, a drilling jar is a downhole tool that delivers a strong impact to
stuck components in the wellbore, either mechanically or hydraulically.

6. Tongs
Large, clamp-like tools used on the rig floor to make up (tighten) or break out (loosen) pipe
connections. Hydraulic or manual versions are used depending on rig type.

Page | 39
\

Page | 40
 4 . SECONDARY RECOVERY & UTILITY DEPARTMENT
The Secondary Recovery & Utility (SR & U) Section of Oil India Limited is a vital unit under
the Oil & Gas Production Services (OGPS) Department that focuses on enhancing oil recovery
from mature and declining wells. Primary recovery methods alone are often insufficient to extract
the maximum possible reserves from a reservoir. Hence, SR & U implements various secondary
recovery techniques, such as water flooding, gas injection, and steam stimulation, to
maintain reservoir pressure and improve the displacement of hydrocarbons towards production
wells.

The section is also responsible for operating and maintaining boilers, mobile steam generators
(MSGs), and other utility equipment that are essential for well stimulation and enhanced oil
recovery (EOR) activities. Additionally, SR & U plays a crucial role in resource management,
ensuring the efficient use of utilities like water, steam, and power in support of field operations.

Through continuous monitoring, operational support, and field interventions, the SR & U Section
contributes significantly to boosting oil production, optimizing resource utilization, and
extending the economic life of oilfields in challenging production environments.

Page | 41
 4.1 BOILER
As per IBR-1950, “Boiler” means any closed vessel exceeding 22.75 liters in capacity which is
used expressively for generating steam under pressure and includes any mounting or other fitting
attached to such vessel, which is wholly or partly under pressure when steam is shut off.

Boiler Elements

Boiler mountings Boiler Accessories

 Fusible plug  Economizer

 Main stream  Superheater
stop valve  Feed water pump
 Auxiliary steam stop  Injector
valve
 Safety valve
 Level gauge glass
 Air Vent
 Feed check valve
 Pressure gauge
 Blowdown valve

Boiler types in OIL:

1. Fire tube boilers-

 Hot flue gases pass through tubes and water surrounds them.
 Types in OIL: Loco type (Manual), Packages type (Automated).
 Example – static boilers.

Advantages:

 No water tubes so no problem of scale deposition.

 Fewer problems of overheating and bursting.

Page | 42
 Disadvantages:

 Lower steam generation rate.

Fig 2.1: Fire tube boiler

2. Water tube boilers-

 Boiler water passes through tubes and hot flue gases surround them
 Requires more skill and careful attention for working.
 Example: MSG units.

Advantages:

 Higher steam generation rate.

 Space requirement less.

Disadvantages:

 Deposition of scale in tubes might cause overheating and bursting of tubes.

Fig 2.2: Water tube boiler

Page | 43
Brief Description of the Boiler:

1. Pressure Part Assembly: Boiler Shell is constructed in suitable sections dependent upon boiler
size. Following the rolling process, longitudinal and circumferential seams are machine welded
and subjected to X-Ray and NDT inspection to comply with the latest standard requirements.
Manholes, Hand-holes etc. are provided as per regulations and the entire shell assembly is mounted
on Saddles. The boiler is of fully wet back design. The furnace tube is designed to allow adequate
expansion and is located between the front tube plate and the totally submerged reversal chamber.
The rear reversal chamber plate is stayed to the boiler rear tube plate with adequate number of stay
bars. The second pass of tubes is fitted between the boiler front tube plate and the reversal chamber
front tube plate. The first tubes are expanded into both tube plates. Third pass tubes are fitted
between the boiler front and rear tube plates and are expanded into position. The required number
of stay tubes and stay bars are fitted in all boilers. All stay tubes are lightly expanded before being
welded in the tube plates and reversal chamber. Access doors permit as far as is practicable, the
internal inspection of heating surfaces and include a main door on top of the boiler shell and one
mud door is provided in the rear tube plate. The furnace is designed with a liberal furnace volume
to reduce the heat flux and keep the volumetric Heat release rate at a lower level. Sufficient water
holding capacity is provided to enable a faster response to fluctuating loads. Adequate steam space
and steam water inter phase area ensures that dry saturated steam is generated from the boiler .

2. Safety features: The boiler is provided with a float operated magnetic water level controller
that regulates the water level inside the boiler. This activates the feed water pump to switch on or
off based on the level of water inside the shell. In case of low water level, an alarm is sounded and
at extra low level, the burner is tripped. Two fusible plugs are provided in the boiler.

3. Feed Water Pumping Station: Two numbers centrifugal multi stage feed water pumps with
motor and base frame are provided to pump the feed water into the boiler. Necessary isolation and
non-return valves are provided in the feed water line between the pump delivery and boiler inlet.

4. Prewired Control Panel (PCL Base): The Power cum control panel is fully pre-wired; powder
coated made out of 22g CR sheet and houses all the switchgears for the drives and instruments for
the boiler. The power and control sections are physically isolated by a partition. All indicating and

Page | 44
display lamps and switched are provided here. Degree of protection is IP 54 and necessary isolation
switch and alarm hooter is provided.

5. Self-supported Chimney: Self-Supported Chimney with Standard Accessories like: Aviation

Lamp, Lighting Arrestor, Earthing Strip, Sampling Pot, Cable, Insulator, Monkey Ladder,
Platforms, Foundation Template with Bolt, Nut & Washer.

6. Feed Water Tank : 2 KL Feed Water Tank with Mountings & Fittings along with Insulation.
Elevation 5mtrs above Boiler on RCC Structure.

7. Single Element Drum Level Control: A Single Element Drum level control is provided for
precise level control in the boiler. This will sense Drum Level and will adjust water flow to keep
drum level constant. This will provide quality (Dry) steam at constant pressure to process.

Page | 45
 Mobile Steam Generator (MSG):
I. Overview
A mobile steam generator, also known as a portable steam generator, is a device that
produces steam on the go, typically for various industrial or commercial applications.
These generators are designed to be easily transportable and can be moved to
different locations as needed. Steam generators utilize water and heat to produce
steam, which can then be used for a wide range of purposes, such as:

a. Flow line Job at OIL installations

b. Tank/Sump Evacuation Job

c. Assistance in well intervention jobs at WSS & WCI
d. GCS maintenance job
e. Drilling Rig cleaning
f. Other miscellaneous jobs
The mobile steam generators come in different sizes and capacities, depending on
the intended application. They are typically fuelled by electricity, diesel, or propane,
allowing for flexibility in various operating environments.

Page | 46
 Mobile Steam Generator operated under Utility Department of OCS5 is
observed, and its specifications are noted and explained. MSG type used is
diesel fired, coil type once through boiler, burner is diesel burner.

a. Parts of MSG:

 Water Chamber (6KL)

 Boiler Chamber

 Power Chamber (Auto)

 Generator

 12volt battery

b. Design Data

 Maximum working pressure of boiler: 42.2 KG/CM²G

 Maximum working steam temperature: 256°C
 Evaporation:1,000 KG/HR(From &at 100°c)
 Fuel: Diesel

Starting of a Mobile Steam Generator

i. Check list before starting MSG unit:
 Feed water tank water level should be normal level.
 LDO tank Diesel Level should be normal level.
 Boiler feed water pump suction valve should be opened.
 Boiler feed water pump discharge valve should be opened.
 All drain valves should be closed.
 Instrument isolation valve should be open.
 LDO Pump suction line valve should be open.
 All strainers shall be clean properly.
 Main outlet steam line to be connects with process.

Page | 47
  D.G. Set & control panel earthing.
 Check blow down valve should be closed.
Operation:

• Generator start power on & MCB on

• Connecting the Earthing.
• Pannel board masters switch on.
• Main steam stop valve open.
• Water pump.
• Blower, damper.
After delivering live water goes out:

• Diesel pump
• Ignition on.
• Boiler firing.
• Cathode & Anode spark.
• Diesel flow.
Closing procedure:
• Main stop valve close.
• Blow down valve open.
• Fire, Diesel, Water pump close.
• Pressure drop too.
• Blow down valve close.
• Main stop valve open.
• Water pump open.

Page | 48
BOILER BATTERY 5

A boiler battery, specifically referring to multiple boilers working together, operates on the principle
of heat transfer to water to produce steam. This is achieved by burning fuel in a furnace to generate
hot gases, which then transfer their heat to water within the boiler, converting it into high-pressure
steam. The steam can then be used for various purposes, such as power generation or industrial
processes.

Fig: Boiler Battery 5 (BB5)

STARTING PROCEDURE OF PACKAGE TYPE BOILER:

The opening procedure for Boiler Battery 5 involves a series of steps to ensure a safe and efficient
start-up. This includes checking water levels, ensuring all necessary valves are open, and gradually
increasing pressure and temperature while monitoring various parameters. Detailed steps vary
depending on whether it's a cold or warm start, and if it's a hot system, specific procedures for that
scenario should also be followed.

Page | 49
Here's a breakdown of the general steps involved:

1. Initial Checks and Preparations:

Confirm Power and Fuel: Ensure power supply to the boiler and fuel systems is available and
switched on.

Check Water Level: Verify the water level in the boiler drum is within the specified range using the
gauge glass.

Check for Leaks: Inspect the boiler and connected piping for any signs of leaks.

Open Necessary Valves: Open the boiler vent valve, feed water valves, and any other relevant valves
as per the specific SOP.

Ensure Proper Draft: Start and regulate the induced draft (ID), forced draft (FD), and primary air
(PA) fans according to furnace requirements.

Start Fuel Handling: If applicable, start the fuel handling system and ensure a consistent fuel supply.

2. Warming Up:

Warm Start: If the boiler is already warm, ensure the boiler is kept in a hot box-up condition and the
drum level is maintained.

Gradual Pressure and Temperature Increase: Gradually increase the boiler pressure and temperature
according to a warm start-up curve.

Monitor Parameters: Closely monitor water level, pressure, and temperature during the warm-up
phase.

3. Cold Start:

Close Main Steam Valve: Ensure the main steam valve is closed before starting the firing process.

Open Vent Valve: Open the vent valve to allow air to escape during the initial firing process.

Start Boiler Feed Pump: Start the boiler feed pump and maintain the drum level.

Page | 50
Fire the Boiler: Ignite the fuel and observe the flame in the combustion chamber.

Monitor Combustion: Ensure proper combustion by observing the flame through the sight glass and
adjust air flow accordingly.

Open Blowdown Valve: Open the blowdown valve periodically to remove any sludge or impurities.

4. Bringing the Boiler Online:

Gradual Pressure Increase: Slowly increase the boiler pressure to the operating pressure.

Monitor Parameters: Continue monitoring water level, pressure, temperature, and other relevant
parameters.

Open Main Steam Valve: Once the boiler reaches operating pressure and temperature, gradually
open the main steam valve.

Close Auxiliary Steam Valve: Simultaneously close the auxiliary steam valve, if used.

Continue Monitoring: Continue to monitor the boiler's performance and make adjustments as
needed.

CLOSING PROCEDURE PACKAGE TYPE BOILER:

To shut down Boiler Battery 5, the procedure typically involves reducing boiler demand, stopping
pulverizers, and closing the main steam stop valve. Afterward, the boiler is depressurized, and the
MFT (Main Fuel Trip) is activated to start purging. The specific steps may vary based on the boiler
type and operational procedures.

Here's a more detailed breakdown of the process:

1. Reduce Boiler Demand: Gradually decrease the boiler load, potentially by reducing pulverizer
demand and/or switching to a different fuel source like LDO (Light Diesel Oil), as per the pulverizer
SOP.

Maintain main steam temperature within the specified range (e.g., 540 +/- 5 degrees Celsius).

Ensure that the SCAPH (Secondary Air Preheater) system is in line to maintain stack temperature.

Page | 51
2. Stop Fuel Supply and Related Equipment: Stop the bottom-most pulverizer (as per pulverizer
SOP) and then subsequent pulverizers one by one while maintaining steam temperature.

Close all oil valves associated with the pulverizers.

Stop the seal air fan (as per its SOP).

Stop the PA (Primary Air) fan and ensure PA fan inlet and outlet dampers are closed.

3. Close Steam Valves and Depressurize: Close the boiler main steam stop valve.

Parallely, remove the HFO (Heavy Fuel Oil) as per the SOP and follow the boiler depressurization
curve.

Open boiler drain valves after the boiler stop valve.

4. Purge and Shutdown Auxiliary Systems: Activate the boiler MFT (Main Fuel Trip) to initiate
boiler purging.

Stop the ID (Induced Draft) fan and IDF (Induced Draft Fan) damper control from hydraulic to
manual as per SOP, and fully open the IDF, PAF (Primary Air Fan), and SAF (Secondary Air Fan)
dampers.

Stop the air ejector system and gland sealing system as per their respective work instructions.

5. Final Checks and Cooling: Ensure the downcomer 1 to economizer R/C line MOV is open
(MOV1809).

Monitor drum level and allow for natural cooling of the boiler.

When drum pressure reaches a low level (e.g., 2 kg/cm²), open SH (Superheater) and drum air vents,
and SH start-up vents.

Open SH header drain to the blowdown tank.

Close the CBD (Continuous Blowdown) if it was open.

6. Safety Procedures: Follow the specific emergency shutdown procedures if needed.

Page | 52
Ensure all vents and drains are open to prevent pressure buildup during cooling.

Inspect the boiler internally and externally before closing it up.

Check for any leaks, scaling, or corrosion and address them as necessary.

Page | 53
 WATER INJECTION SYSTEM
Water injection, also known as waterflooding, is a method used in the oil and gas industry to
enhance oil recovery by injecting water into an oil reservoir. This process increases reservoir
pressure, which helps to push oil towards production wells. It is a form of enhanced oil recovery
(EOR) and is particularly useful in mature oil fields where natural pressure has declined.

Here's a more detailed explanation:

Purpose: Water injection serves two main purposes: maintaining reservoir pressure (voidage
replacement) and sweeping or displacing oil towards production wells.

How it works: Water, often treated seawater, is injected into the reservoir at high pressure through
dedicated injection wells.

Pressure Support: The injected water helps to maintain or restore pressure within the reservoir,
counteracting the natural decline in pressure as oil is extracted.

Displacement: The injected water pushes the oil towards production wells, increasing the amount
of oil that can be recovered.

Enhanced Oil Recovery (EOR): Water injection is a type of EOR technique, which aims to
improve the amount of oil extracted from a reservoir beyond what can be achieved through primary
production methods.

Mature Fields: It is especially valuable in mature oil fields where primary production has
significantly declined due to reduced reservoir pressure.

Fig: Water injection system (WIS#21) No of pumps: 8 Nos

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No of DTW: 8 Nos.
No of injection wells: 11 Nos.

Pump Data:

Type: Reciprocating Pump (Triplex Plunger)

Make: BPCL (4 Nos)

Discharge Pressure: 142 KSC

Discharge Rate: 22 m3/hr

RPM: 200

Make: National Oil Well (NOW)

Maximum working pressure (Discharge Pressure): 159 KSC

Rated BHP: 160 HP (119 KW)

Gear Box:

Make: Greaves Gear

Ratio: 5.06:1

DTW:

Type: Vertical Turbine (12.5 HP) (2 Nos)

Make: WPIL LTD.

Capacity: 45 KL/Hr (Approx)

No of stages: 5

Pump size: 150 mm Speed : 2900 RPM

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 CONCLUSION
The 30-day internship at the Oil & Gas Production Services (OGPS) Department of Oil India
Limited has been an enriching and insightful experience, providing a practical understanding of
the complex operations involved in sustaining oil production from mature fields. Through
structured visits and interactions with the teams from Workover Technical Services, Workover
Operations, and the Secondary Recovery & Utility (SR & U) Section, we gained firsthand
exposure to vital field activities such as workover rig operations, equipment maintenance
protocols, well intervention techniques, and secondary recovery processes.

This internship not only bridged the gap between theoretical knowledge and real-world
applications but also deepened our appreciation of the technical challenges, safety standards, and
operational strategies that drive Oil India’s production efficiency. The experience has enhanced
our technical competencies and provided a solid foundation for understanding the dynamic nature
of upstream oilfield operations.

The learnings and observations from this internship will undoubtedly serve as valuable assets in
our future professional endeavors within the oil and gas sector

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